Deluxe Lw Fiber Optic Cable Blower

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

USER'S GUIDE & SAFETY MANUAL

Deluxe LW Blower Patent Pending

CONDUX 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Important Safety Notice Read and understand all procedures and safety instructions before using the Deluxe LW Blower. Observe all safety information on this page and note specific safety requirements as explained by procedures in this manual. Failure to follow these instructions could result in serious personal injury or death.

ADVERTENCIA: Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si Ud. no comprende las instrucciones favor de consultarle a su jefe.

READ MANUAL FIRST

Save this user’s guide for future reference. COMMUNICATIONS WITH THE MANUFACTURER For any information related to the machine (use, maintenance, spare parts) always state Model, Serial Number, Manufacturing Year and Order. This data can be found in the machine identification table. European Representative: Tesmec S.p.a. Via Trento, 26-24035 CURNO (BG)-Italy Tel: 39-035611218 Fax: 39-035616323 http://www.tesmec-group.com email: [email protected]

Manufacturer: Condux International Inc. 145 Kingswood Rd Mankato, MN 56002-0247 1-507-387-6576 Fax 1-507-387-1442 Internet: http://www.condux.com E-mail: [email protected]

If you have questions on: SAFETY - OPERATIONS - APPLICATIONS CALL 1-800-533-2077

CONDUX 2 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Table of Contents 1 2

3

4

5 6 7 8 9 10 11

12

13

14 15

16

5 Blue Heron Drive

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 A. Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 B. Condition of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 C. Air Compression Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 D. Operational Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 E. Electronic Counter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F. Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 G. Acoustic Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 H. Caterpillar Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 I. Conduit Coupling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safe Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 B. Hydraulic Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 C. Pneumatic Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 D. Electric Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Unpacking the Deluxe LW Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A. Blower Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B. Tools and Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Set Up the Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Attach Blower to Job Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cable Crash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pressure Test Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Prepare Conduit for Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Prepare Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Final Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Blower Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 A. Observer at Exit Pit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 B. Connect Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 C. Set up the Electronic Counter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 D. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Tear Down Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. Remove Power from Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. Remove Cable from Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 C. Separate Unit from Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A. Track Cleaning & Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 B. Replacement of Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 A. Blower with Job Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 B. Upper Drive Shaft Replacement Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 C. Lower Drive Shaft Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 D. Hydraulic Motor Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E. Idler Bracket Bushing & Idler Bracket Screw Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 F. Air Block Assembly Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 G. Counter Clamp Roller & Cable Guide Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 H. Timing & Takeup Roller & Idler Roller Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 I. Hydraulic Coupler (Male) Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 J. Hydraulic Coupler (Female) Replacement Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 K. Clamp Adjustment Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 L. Lower Counter Roller Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 M. RH Cable Guide Roller Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 N. LH Cable Guide Roller Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 O. Counter Spring Replacement Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 P. Basemount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Q. Pneumatic & Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 R. Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 S. Suggested Hydraulic Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 T. Possible Wear & Replacement Parts & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

3

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

General Information

1.

The operating instructions contain a full description of the Deluxe LW Blower, which has been designed for the purpose of feeding fiber optic cable through round conduits of uniform cross section. The conduit must previously have been installed underground or overhead to receive the fiber optic cable and must be of sufficient length on exit to be received by the machine. The conduit must be made of material with sufficient compression strength for it to be adequately sealed in the exit of a machine. The conduit must be airtight up to a pressure of 175 psi (12 bar). For this purpose, connectors of screw, compression or fusion type must be used. Conduits from 1" (25.00 mm) to 1.97" (50.00 mm) and fiber optic cables from 1/4" (6 mm) to 1.13" (28.7 mm) diameter can be accepted by the machine. Fiber optic cable is fed into the conduit by combining pulling and pushing forces, which draw the fiber optic cable through the conduit. The pulling force is achieved by connecting the leading end of the fiber optic cable to a piston or carrier, which fits exactly into the conduit to make an airtight seal. Air under pressure is fed in behind the carrier causing it to be forced through the conduit. As the carrier moves through the conduit, it pulls the fiber optic cable behind it. The fiber optic cable is continuously pushed into the conduit by a tractor drive. This consists of two caterpillar tracks, which grip the top and bottom of the fiber optic cable moving it into the conduit. This ensures the fiber optic cable is always free as it moves into the conduit and reduces the magnitude of the pulling forces needed to carry the leading end through. Special lubricants are used to make it easier for the carrier to pass through the conduit. The exit of the machine consists of an air box that is made in two halves that clamp together. The air box contains special removable seals on entry and exit, which clamp around either the end of the conduit or the fiber optic cable to be fed into the conduit. The seals can be changed to accommodate different conduit and fiber optic cable sizes. The conduit is clamped between a pair of seals at the entrance to the air block. A clamp located in front of the entrance to the air block holds the conduit mechanically to prevent it from moving axially. The fiber optic cable enters through two seals located in an aluminum nozzle that splits in half. The aluminum nozzle is located in the entrance to the air box and is shaped to ensure an airtight seal around the fiber optic cable. When the two halves of the air box are closed, air pressure is admitted into the space between the seals on entry and exit. The use of the Deluxe LW Blower for operations different from those discussed in this manual are considered extremely dangerous and thus forbidden. The non-respect for the prescribed restraints of the machine causes a situation of improper use and relieves the manufacturer from any responsibility, civil or penal. The manufacturer’s responsibility declines even when one of the following happens: a. The consequences caused by tampering and/or modifications carried out without the manufacturer’s written acceptance. b. The use of imitative spare parts. c. Bad maintenance. d. Use with disconnected safety devices. e. The connection to machine and/or parts not produced and not directly authorized by the manufacturer in a written acceptance. The Deluxe LW Blower is a unique device for inserting fiber optic cable directly into conduit. The Deluxe LW Blower is comprised of an air block and a tractor drive that, when combined with an air compressor and a hydraulic power unit, will propel fiber optic cable measuring from 1/4" to 1.13" (6 mm to 28.7 mm) into an unobstructed, unoccupied, airtight conduit run at speeds of 0 to 300 feet per minute (0-91 m/min). A cable carrier must be placed at the front end of the cable.

4 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

The Deluxe LW Blower greatly reduces pulling stress on the cable. When equipped with the electronic counter box, the tractor drive will automatically shut down if the cable hits an obstruction or if it begins to slip on the tractor drive. The blower comes standard with job box, hydraulic hoses with couplings, digital LCD electronic counter box, and an adjustable control valve to the tractor drive for speed adjustment. GENERAL MACHINE USE a. Only qualified operators should use the machine. The operator should only be the person who received qualified training from the product owning company or trained by the manufacturer. b. Machine must only be used for the work it was designed for. c. Machine is not to be used with unauthorized personnel on the job site. d. Should there be any doubt concerning use, functioning, maintenance or anything else, please contact the factory or factory representative. OPERATOR QUALIFICATIONS a. Operator must know the required safety directives to run the machine that are pertinent to the country where it is being used. b. Operator in charge of the machine and installation project must be appropriately dressed, avoiding large clothes, hanging jewelry or whatever might become entangled in the moving parts. c. Operator must also wear the necessary protective equipment such as gloves, boots, helmet, etc. d. Operator must carefully follow all advisements contained in the instruction manual or on the machine. e. Operator must have work area kept clean of obstacles that might inhibit a safe working area. MAINTENANCE QUALIFICATION a. All of the machine maintenance must be carried out with the machine on a level surface and not attached to any form of power source: electrical, pneumatic, nor hydraulic. b. Authorized and trained personnel must do all maintenance operations. Trained personnel are defined as people who have received qualified training from the using company or from the manufacturer.

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

5

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Technical Information

2.

A. HYDRAULIC SYSTEM REQUIREMENTS • Hydraulic Operating Pressure: 1500 psi (103 bar) maximum • Hydraulic Flow: 5.5 gpm (20.8 l/m) maximum • Hydraulic Circuit Type: Open Center • 5 micron filtration • Fitted with BHTMA standard 1/2" flat faced quick release couplings • Proper sized power unit should be used to run the blower machine to prevent overheating IMPORTANT: Operators must take any precautions that may have been recommended by the suppliers of lubricants or hydraulic fluids. This applies to the use and disposal of lubricants and hydraulic fluids including the lubricant used to ease the passage of fiber optic cables through conduits. B. CONDITION OF USE Temperature from 21° F ( -6° C) to 110° F (+43° C) Humidity from 30% to 90% +/- 5% Weather conditions relevant to working conditions Natural and/or artificial lighting of the work site, minimum 200 lux C. AIR COMPRESSOR REQUIREMENTS • Pneumatic Pressure: 175 psi (12 bar) Maximum • Required Flow Capacity: 375 SCFM (11 m3/min) Maximum • Conduit Size: 1"-1.97" (25 mm-50 mm) OD • Air coolers are recommended for blowing fiber • Compressor flow may be doubled if blown distance is greater than 3,500 feet (1,067 meters) • Air hose fittings need to be compatible with Dixon “Air King” universal couplings. The following charts help to determine the compressor size requirement based on testing the conduit system (Figures 1-3). 1. Pressurize the conduit up to the maximum compressor pressure. That is the Pstart - value. 2. Time for 10 seconds and record the ending pressure, Pend. 3. Subtract Pstart-Pend and divide by 10. 4. Find the appropriate x value and approximate length of conduit run then correlate that information with the size of the conduit on the graph. The resulting zone is the approximate compressor requirement.

6 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

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Figure 2. Compressor Sizing for 4,921 ft (1,500 m) of Conduit Run

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Figure 3. Compressor Sizing for 8,202 ft (2,500 m) of Conduit Run 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

7

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

D. OPERATIONAL CAPACITIES • Pushing Force: 175 lbs (778 N) maximum • Pushing Speed: 300 ft/min (91 m/min) maximum • Cable Sizes: .25" to 1.13" (6 mm to 28.7 mm) • Conduit Sizes: 1", 1-1/4" TRUE, 1-1/4", 1-1/2" SDR 11 & 13.5 and metric O.D. conduit; 25 mm, 32 mm, 36 mm, 37 mm, 40 mm, 42 mm, 44 mm, 46 mm and 50 mm E. ELECTRONIC COUNTER BOX • Power Requirements: 12 volts DC • Power consumption is 24 Watts • Power connection must be to automotive power point or power point connection on Condux hydraulic power unit • Fused with a 2.5 amp fuse, 250 volt-5x20mm-GMA type • Displays: Total Machine Distance, Distance of Run, Operational Speed, Errors Descriptions • Automatic Shutdown Speeds: 20 ft/min (6.2 m/min) minimum 300 ft/min (91 m/min) maximum F. PHYSICAL SPECIFICATIONS (DOES NOT INCLUDE LEGS OR JOB BOX) • Height 16.5" (419 mm) • Length 30" (761 mm) • Width 14.8" (375 mm) • Weight 82 lbs (37 kg) G. ACOUSTIC EMISSION • Level of max. sound pressure to the operator seat (ISO 11202) Lep=85 dB(A) H. CATERPILLAR DRIVE SPECIFICATIONS • Maximum pushing force: 175 lbs (778 N), depending on cable diameter • Maximum pushing speed: 300 ft/min (91.5 m/min) • Maximum clamping force: <114 lbf/in (20 N/mm) • Independent pushing drive belts with polyurethane pads profiled for cable 0.23" (5.8 mm) to 1.13" (28.7 mm) • Mechanical gas charged shock absorber clamp to prevent cable crush. • Side guards. I. CONDUIT COUPLING REQUIREMENTS • Must withstand maximum air pressure of 175 psi (12 bar). • Must withstand axial loading and vibration. • Must be screw type, compression type, or fusion type. • Sight Holes must be sealed. • Must fit snugly. • Conduit ends must be cut off squarely and deburred. • Conduit must be fully seated into the coupler. • Couplers should be installed in a straight section of conduit. • Must be same size conduit.

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Safe Operating Practices Read and understand all procedures and safety instructions before using the Deluxe LW Blower. Observe all safety information on this page and note specific safety requirements as explained by procedures called out in this manual. Failure to follow these instructions could result in serious personal injury, property damage or death. A. WORK AREA SAFETY 1. Wear personal protective equipment: hard hat, safety glasses, safety shoes, and leather work gloves. 2. The safe operation of this equipment requires that the operators be on stable footing. 3. Stay clear of cables or lines under tension. 4. Stay clear of pressurized line and conduit. 5. Stay out of manhole while blower is in use. 6. Use the blower only for its intended purpose. Do not use the tractor drive without the air block to push or pull cable. 7. Do not place cable reel too close to unit. Place the reel far enough away from the unit to ensure proper control. 8. Do not tamper with relief valves or pressure reducing valves. 9. Place cable grip on end of conduit to catch cable carrier and cable. 10. Keep hands away from tractor drive while blower is in operation.

3.

B. HYDRAULIC DEVICES Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards: 1. Tighten all connections before applying pressure. Relieve pressure when connecting or disconnecting hoses when servicing the unit. 2. Check for leaks with a piece of cardboard. Do not use your hands! 3. Do not exceed working pressure of hydraulic hoses. 4. Visually inspect hoses regularly and replace if damaged. C. PNEUMATIC DEVICES The Deluxe LW Blower is a pneumatic device, using pressurized air to project cable at high velocities. Please observe the following precautions when operating the blower: 1. Forced air creates flying debris. Always wear personal protective equipment. Severe personal injury could result. 2. Ensure no personnel are in the destination access vault during the blowing operation. Severe personal injury could result.

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D. ELECTRIC DEVICES The electronic counter box and power supply are electrical devices. Electric shock hazards exist that could result in severe personal injury or death. Observe the following precautions to avoid electrical hazards: 1. Do not operate in or near water. This includes setting the electronic counter box or battery pack on a wet surface or exposing them to rain. 2. Do not remove cover of electronic counter box. There are no user-serviceable parts inside. Refer servicing to qualified service personnel. 3. The electronic counter box power switch should be in the off position before connecting or disconnecting any cords.

Unpacking the Blower

4.

A. BLOWER COMPONENTS Each Deluxe LW Blower Package contains the following items. • Hydraulic hose from hydraulic control assembly to hydraulic power unit • Owner’s Manual • Shipping Crate • Allen Wrench (3/32") • Allen Wrench (2.5 mm) • Flat face - pin style spanner wrench 1.00" dia. hole pattern w/ .187" dia. pins • 5/8" x 600 lb. Swivel • Venturi Air Plug • Plastic Divided Case w/Parts Label • Parts and User Manual • 1 Qt. Blowing Lubricant • Capscrew Set (10) (M04-0.7’s) • O-Ring Seal Kit NOTE: If any parts are missing: please contact your Condux representative or call Condux International at 1-800-533-2077 (USA or CANADA), or 1-507-387-6576. B. TOOLS AND MATERIALS REQUIRED The tools and materials are necessary to connect the Deluxe LW Blower to a hydraulic power source, and to change the inserts: 1. Allen Wrench (3/32") (included) 2. Allen Wrench (2.5 mm) (included) 3. Allen Wrench (5 mm) (included) 4. Spanner wrench (included) 5. Screwdriver, Flat 6. Screwdriver, Phillips

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Set Up the Blower This manual contains setup and operating instructions for the Deluxe LW Blower with job box. IMPORTANT: The Deluxe LW Blower must not be located below overhead gantries, power lines or walkways where there might be a risk of falling objects. The operator must be wearing recommended protective gear before operating the blower. Operating light levels should be at least 200 lux of light intensity.

5.

A. ATTACH BLOWER TO WORK BOX CAUTION: The machine should be removed with two people or lifted mechanically by the lift rings located on the top of the machine (Figure 4). IMPORTANT: The Deluxe LW Blower should not be parked on a slope in excess of 13°. It should not be parked on a side hill of more that 15°. Remove the ball detent pin from the bottom of the blower. Attach the Deluxe LW Blower to the job box by aligning the guide tracks on the bottom of the blower with the channel on the top of the box. Holes in the box channel need to align with holes on the blower guide track. Once aligned, replace ball detent pin so it locks the blower in place (Figure 5). Lift Rings

Figure 5. Replace Ball Detent Pin

Figure 4. Lift out Blower with Lift Rings

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Cable Crash Test

6.

Cable Crash Testing is a very quick and easy step to be completed before attempting the installation of cable with the Deluxe LW Blower. This test is necessary to set the hydraulic motor pressure of the blower below the point that it may cause cable damage as a result of over pushing or encountering an obstruction in the sub-duct system. Every cable has different pushing values and these values vary depending on duct I.D. Example: A cable with a crash test value of 75 bar in 33 mm I.D. duct, may have a crash value of only 60 bar in a 40 mm I.D. duct. This is because the area of lateral movement is larger as the duct size increases. !CAUTION: Always wear protective equipment: hard hat, safety glasses, safety shoes and work gloves. NOTE: The hydraulic motor pressure adjustment will have no effect on the installation speed of the blowing unit. This is not a flow adjustment. This is a pressure adjustment to prevent damage to the cable that can be caused by excessive pushing force. IMPORTANT: For the Crash Test to work properly use the same size cable and duct that will be used for the job. Set the hydraulic motor pressure on your Deluxe LW Blower using the following procedure: 1. Attach 12' (4 m) of duct to the Deluxe LW Blower (Figure 6). 2. Install Conduit Pulling Eye on the receiving end of the duct (Figure 7).

Figure 6. Placement of Conduit in Conduit Seal & Conduit Clamp

Figure 7. Installing Conduit Pulling Eye

3. Cut a piece of fiber optic cable 15' (5 m) long. This is your test piece of cable.

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4. Attach the correct size Venturi to fit the cable being installed (Figure 8).

HYDRAULIC POWER SOURCE HYDRAULIC HOSES

INNERDUCT

DELUXE LW BLOWER

ELECTRICAL HOOK UP TO POWER SOURCE

FIBER OPTIC CABLE

CABLE REEL

OPERATOR

AIR HOSE AIR COMPRESSOR

Figure 9. Typical Set-Up

Figure 8. Install Venturi

5. Attach Hydraulic Hoses (Figure 9). The Deluxe LW Blower’s hydraulic system uses quick-disconnect couplings. Keep all connections clean to avoid contamination and possible system failure. Use hose end caps (supplied). A contaminated hydraulic system will effect the operation of the cable blower and may invalidate your product warranty. Take caution in routing the hoses to prevent a tripping hazard. Follow these steps to connect the hydraulic components: A. Attach the quick-disconnect couplings to the hydraulic power supply (Figure 10).

Figure 10. Attach Hydraulic Hoses

B. Start the hydraulic power unit and check all connections for leaks with a piece of cardboard. In cold weather, run hydraulic power supply until hydraulic oil warms up. WARNING: Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards: • Tighten all connections before applying pressure. Relieve pressure before connecting or disconnecting hoses. • Check for leaks with a piece of cardboard. Do not use hands! • Do not exceed working pressure of hydraulic hoses. Visually inspect hoses regularly and replace if damaged. C. Run the blower for approximately 1 minute to remove any trapped air and then stop the blower and hydraulic power source. 5 Blue Heron Drive

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6. Remove the Cap/Cover from the stem of the Relief Valve (Figure 11). 7. Loosen Jamb Nut (Figure 12).

Figure 12. Loosen Jamb Nut

Figure 11. Remove Cap of Relief Valve

8. Loosen Hex Screw on the Relief Valve, turn counter-clockwise, until it stops (Figure 13). 9. Place Cable in Blower from Rear Rollers through Tractor Drive. Push cable through the duct until it stops against the Pulling Eye (Figure 14).

Figure 13. Loosen Hex Screw on the Relief Valve

Figure 14. Install Cable

10. Place a mark on the Cable about 2" (51 mm) behind the Rear Rollers (Figure 15).

14

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Figure 15. Mark the Cable Fax: (610) 831-5012

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11. Install top Venturi (Figure 16). Close Air Block and tighten (Figure 17).

Figure 17. Close Air Block and tighten

Figure 16. Install Top Venturi

12. From the Rear Rollers, pull out approximately 8' (2.4 m) of cable from the blower. 13. Set the Hydraulic Flow Control to the highest speed by rotating the flow control knob counter-clockwise. 14. Lower the Tractor Drive Cover, and tighten until it stops on the Stopper- Bushing. 15. Turn on Hydraulic Power. If cable does not move, turn off Hydraulic Power and go on to step 16. If cable moves, allow it to move until it stops. Note pressure. Turn off Hydraulic Power and go on to step 17. 16. Turn Hex Screw on the Relief Valve 1 full rotation (clockwise) (Figure 18). Return to step 15.

Figure 18. Turn Hex Screw on the Relief Valve

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17. Raise Tractor Drive Cover. Pull out 8' (2.4 m) of cable from the blower. 18. Lower and tighten Tractor Drive Cover. Turn Hex Screw on Relief Valve 1 full rotation (clockwise). 19. Turn on Hydraulic Power. Allow cable to move until it stops. Note pressure. Turn off Hydraulic Power. 20. Repeat steps 16-19 until cable folds over or you reach 1500 psi. Note the pressure. You will notice cable fold-over because the line drawn on the cable will disappear inside the machine or duct (Figure 19).

Figure 20. Tighten Jamb Nut

Figure 19. Cable folds over

21. Turn Hex Screw on Relief Valve 1 full rotation counter-clockwise. 22. Remove folded fiber and test again at current Relief Valve settings to ensure no fiber fold over or damage occurs. 23. Remove test piece of fiber optic cable. 24. Tighten Jamb Nut in place (Figure 20). 25. Replace Cap/Cover on Relief Valve. 26. Re-adjust Flow Control setting to the slowest speed setting. 27. Remove test duct piece from the Deluxe LW Blower. 28. Crash test is complete.

16 5 Blue Heron Drive

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Pressure Test Conduit The conduit system must be able to withstand a maximum pressure of 175 psi, and be free of leaks. A Conduit Pressure Test Kit, part number 08761457, is available to perform this test. Conduit may also be tested for pressure using the Deluxe LW Blower, follow the steps below. 1. Loosen the 6 spanner nuts on the Air Block assembly using the spanner wrench (Figure 21). Open the Conduit Clamp Cover and Air Block Cover (Figure 22).

7.

Figure 22. Open Conduit Clamp Cover & Air Block Cover

Figure 21. Loosen Air Block Assembly

2. Select the correct Conduit and Cable Components according to conduit and cable size. Refer to the Conduit and Cable Pack selection charts (Tables 1 and 2, page 18). 3. Choose the correct Conduit Seal and install both halves securely. Use the provided 2.5 mm hex wrench (Figure 23). 4. Choose the correct Conduit Clamp and install both halves (same color as the conduit seal). Use the provided 2.5 mm hex wrench (Figure 24).

Figure 24. Install Conduit Clamp

Figure 23. Install Conduit Seal 5 Blue Heron Drive

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CABLE PACK Cable OD P/N

Cable OD

P/N

1

0.23-0.34 (5.8-8.8)

08780393 Pack #1

0.23-0.34 (5.8-8.8)

08780281 Purple

0.35-0.48 (8.9-12.2)

08780282 Blue

2

0.35-0.60 (8.9-15.2)

08780394 Pack #2 0.49-0.60 (12.3-15.2)

08780283 Green

0.61-0.73 (15.3-18.5)

08780284 Red

3

0.61-0.85 (15.3-21.6)

0.74-0.85 (18.6-21.6)

08780285 Gold

0.86-0.97 (21.7-24.6)

08780286 Clear Alum.

0.98-1.13 (24.7-28.7)

08780446 Black

0.43-0.55 (11.0-14.0)

08780111 Orange

PACK

4 5 6

VENTURI

08780395 Pack #3

0.86-1.13 (21.7-28.7)

08780396 Pack #4

0.43-0.55 (11.0-14.0)

08780245 Pack #5

!""#$%#&'(#!)$*(

Pack #6

CABLE SEAL Cable OD P/N 0.23-0.28 08780406 (5.8-7.2) 0.29-0.34 08780407 (7.3-8.8) 0.35-0.42 08761424 (8.9-10.7) 0.43-0.48 08761425 (10.8-12.2) 0.49-0.55 08761426 (12.3-14.0) 0.56-0.60 08761427 (14.1-15.2) 0.61-0.67 08761428 (15.3-17.0) 0.68-0.73 08761429 (17.1-18.5) 0.74-0.79 08761430 (18.6-20.1) 0.80-0.85 08761431 (20.2-21.6) 0.86-0.92 08761432 (21.7-23.4) 0.93-0.97 08761433 (23.5-24.6) 0.98-1.04 08761434 (24.7-26.4) 1.05-1.13 08761435 (26.5-28.7) 08780116 0.45-0.49 (11.4-12.4) 08780117 0.50-0.55 (12.7-14.0)

CABLE GRIP Cable OD

P/N

0.21-0.35 (5.3-8.9)

08643754 033-29-1194

0.32-0.48 (8.1-12.2)

08643755 033-29-1195

0.42-0.61 (10.7-15.5)

08643756 033-29-1196

0.53-0.74 (13.5-18.8)

08643757 033-29-1197

0.64-0.87 (16.3-22.1)

08643758 033-29-1198

0.75-1.00 (19.1-25.4)

08643759 033-29-1199

1.00-1.24 (25.4-31.5)

08643137 033-03-013

0.42-0.61 (10.7-15.5)

08643756 033-29-1196

!""#$%#&'(#+)$*(,#+*+-"+)"(#$."/#$.#-.-&-+"#01#2-)(3#45&-6#7+)"(#8"$9(3#$3:(3

Table 1. Cable Packs

PACK

1 2 3 4 5 6 7 8 9 10 11 12 13 14

DUCT PACK Duct Size P/N

DUCT CLAMP Duct OD P/N

DUCT SEAL Duct OD P/N

CARRIER Carrier P/N

FOAM CARRIER arrier OD P/N

CABLE GRIP Duct OD P/N

INNERDUCT EYE ID Range

1" SDR 11/13.5

08780386 Pack #1

1.315 (33.4)

08780369 Blue

1.315 (33.4)

08780307 Blue

1.121 (28.5)

08761811

1.25 (31.8)

08761439

1.00-1.24 08643137 (25.4-31.5) 033-03-013

1.10-1.50 (27.9-38.1)

1.25" SDR 11/13.5

08780392 Pack #2

1.66 (42.2)

08780375 Green

1.66 (42.2)

08780051 Green

1.414 (35.9)

08761817

1.5 (38.1)

08761440

1.50-1.99 08643149 (38.1-50.5) 033-03-016

1.10-1.50 (27.9-38.1)

1.5" SDR 11/13.5

08780397 Pack #3

1.9 (48.3)

08780404 Red

1.9 (48.3)

08780398 Red

1.618 (41.1)

08761819

1.75 (44.5)

08761441

1.50-1.99 08643149 (38.1-50.5) 033-03-016

1.34-1.74 (34.0-44.1)

All of the

./012

Pack #4

All of the above, available only on initial LW Fiber Optic Cable Blower order

25 mm

08780240 Pack #5

0.984 (25.0)

08780099 Orange

0.984 (25.0)

08780134 Orange

0.787 (20.0)

08780230

1.25 (31.8)

08761439

1.00-1.24 08643137 (25.4-31.5) 033-03-013

0.63-1.00 (16.0-25.4)

32 mm

08780385 Pack #6

1.26 (32.0)

08780368 Gold

1.26 (32.0)

08780306 Gold

1.063 (27.0)

08761810

1.25 (31.8)

08761439

1.25-1.49 08643143 (31.8-37.8) 033-03-015

0.80-1.25 (20.3-31.7)

36 mm

08780387 Pack #7

1.417 (36.0)

08780370 Red

1.417 (36.0)

08780308 Red

1.181 (30.0) 1.220 (31.0)

08761812 08761813

1.25 (31.8)

08761439

1.25-1.49 08643143 (31.8-37.8) 033-03-015

1.10-1.50 (27.9-38.1)

37 mm

08780388 Pack #8

1.457 (37.0)

08780371 Blue-Gray

1.457 (37.0)

08780309 Blue-Gray

1.22 (31.0)

08761813

1.25 (31.8)

08761439

1.25-1.49 08643143 (31.8-37.8) 033-03-015

1.10-1.50 (27.9-38.1)

1.25" TRUE

08780389 Pack #9

1.5 (38.1)

08780372 Clear Alum.

1.5 (38.1)

08780333 Clear Alum.

1.25 (31.7)

08761814

1.5 (38.1)

08761440

1.25-1.49 08643143 (31.8-37.8) 033-03-015

1.10-1.50 (27.9-38.1)

40 mm

08780390 Pack #10

1.575 (40.0)

08780373 Black

1.575 (40.0)

08780334 Black

1.299 (33.0)

08761815

1.5 (38.1)

08761440

1.50-1.99 08643149 (38.1-50.5) 033-03-016

1.10-1.50 (27.9-38.1)

42 mm

08780391 Pack #11

1.653 (42.0)

08780374 Blue-Gray

1.653 (42.0)

08780335 Blue-Gray

1.378 (35.0)

08761816

1.5 (38.1)

08761440

1.50-1.99 08643149 (38.1-50.5) 033-03-016

1.10-1.50 (27.9-38.1)

44 mm

08780545 Pack #12

1.732 (44.0)

08780546 Gold

1.732 (44.0)

08780547 Gold

1.496 (38.0)

08761822

1.5 (38.1)

08761440

1.50-1.99 08643149 (38.1-50.5) 033-03-016

1.10-1.50 (27.9-38.1)

46 mm

08780460 Pack #13

1.811 (46.0)

08780466 Blue

1.811 (46.0)

08780461 Blue

1.299 (33.0)

08761815

1.50 (38.1)

08761440

1.50-1.99 08643149 (38.1-50.5) 033-03-016

1.10-1.50 (27.9-38.1)

50 mm

08780575 Pack #14

1.969 (50.0)

08780435 Blue

1.969 (50.0)

08780431 Blue

1.606 (40.8)

08761818

2 (50.8)

08761442

1.50-1.99 08643149 (38.1-50.5) 033-03-016

1.34-1.74 (34.0-44.1)

Table 2. Conduit Packs 18 5 Blue Heron Drive

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5. Choose the correct Venturi to fit the cable being installed. Do not install at this time! 6. Place conduit in the Conduit Seal and Conduit Clamp. Note placement up to ridge on Conduit Seal (Figure 25). 7. Clamp conduit in place (Figure 26).

Figure 25. Placement of Conduit in Conduit Seal & Conduit Clamp

Figure 26. Clamp Conduit in Place

8. Place Seal Disk in Venturi slot. (Figure 27). 9. Close Air Block Cover and secure (Figure 28). Tighten spanner nuts securely, but do not over tighten. Use a cross-tightening procedure.

Figure 28. Tighten Air Block Cover

Figure 27. Installing Seal Disk

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10. Plug receiving end of Conduit with a properly sized Conduit Pulling Eye (Figure 29) (Appendix R pg. 62). 11. Choose the correct Pulling Grip & install on receiving end of Conduit (Figure 30).

Figure 30. Installing Pulling Grip

Figure 29. Installing Conduit Pulling Eye

12. Connect the Air Compressor (Figure 31). a. Ensure Air Valve is off before connecting air hose. b. Attach the hose supplied with the air compressor to the air compressor coupling. The blower air valve assembly is equipped with a claw type connector. Use safety clips on all pneumatic hose connections (Figure 32). c. Observe all safety procedures. d. Route all hoses properly to prevent tripping over them. !WARNING: Forced air creates flying debris. Always wear personal protective equipment. Severe personal injury could result. !WARNING: Ensure no personnel are in the destination access vault during the blowing operation. Severe personal injury could result.

HYDRAULIC POWER SOURCE HYDRAULIC HOSES

INNERDUCT

DELUXE LW BLOWER

ELECTRICAL HOOK UP TO POWER SOURCE

FIBER OPTIC CABLE

CABLE REEL

OPERATOR

AIR HOSE AIR COMPRESSOR

Figure 31. Typical Connections 20 5 Blue Heron Drive

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Figure 32. Installing Air Hose with Safety Clips Fax: (610) 831-5012

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13. Slowly open Air Control Valve. Pressurize conduit to 80-100 psi (5.5-6.9 bar) (Figure 33).

Figure 33. Open Air Control Valve

Figure 34. Close Air Control Valve

14. Prove conduit integrity. a. Close Air Control Valve (Figure 34). b. Conduit must not lose more than 20 psi (1.38 bar) over a 2-minute period. c. After 2 minutes, relieve air pressure. Open air pressure relief valve by moving the blower pressure valve handle counter clockwise to the 9 o’clock position (Figure 35). d. If conduit fails to hold required pressure, check entire conduit run for leaks and repair them. e. Repeat the pressure test until all leaks are found and repaired. !WARNING: Air Block Assembly contains compressed air when blower is operated. Opening Air Block while under pressure may cause serious personal injury. Ensure blower is depressurized before removing Air Block cover, or removing conduit pulling eye. 15. Decompress the Air Block by turning the Air Valve to the 9 o’clock position. Shut off the air at the compressor, decompress the air hose and disconnect the air hose from the fiber blower.

Figure 35. Decompress Air Block

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Prepare Conduit for Cable

8.

1. Remove Conduit Pulling Eye and Pulling Grip from receiving end of Conduit. After removing pulling eye, re-install pulling grip in order to catch Foam Carrier during conduit lubrication (Figure 36). 2. Open the Air Block Cover (Figure 37).

Figure 36. Install Pulling Grip on Conduit

Figure 37. Open Air Block Cover

3. Tilt Blower forward (Figure 38). 4. Pour recommended (silicon-based) lubricant into Conduit opening before Foam Carrier: 1 quart/6000 feet (1 liter/2 km) (Figure 39) (See Appendix T for lubricant ordering information).

Figure 38. Loosen Handle to Tilt Blower

Figure 39. Pour Lube into Conduit

5. Insert Foam Carrier (selected according to conduit size) into Conduit (Figure 40) (See Table 2 on page 18). 6. Insert Seal Disk in venturi slot if not already in place. (Figure 41).

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Figure 41. Insert Seal Disk

Figure 40. Insert Foam Carrier

7. Close the Air Block Cover. Tighten spanner nuts securely, but do not over tighten (Figure 42). Use cross tightening procedure with the spanner wrench to secure completely.

Figure 43. Close Air Control Valve

Figure 42. Tighten Air Block Cover

8. Prove conduit integrity and spread lubricant through Conduit. a. Re-connect the air hose to the fiber blower and attach all safety clips. b. Turn the Air Control Valve handle to the 12 o’clock position and turn on the air from the compressor (Figure 43). c. Slowly open Air Control Valve by turning to the 3 o’clock position. d. Blow Foam Carrier through conduit to spread lubricant and check for blockage. Follow all safety precautions. e. After the Foam Carrier exits, close Air Control Valve. NOTE: Foam Carrier must exit in a reasonable time, allow for approximately 10 seconds per 1,000 feet (300 m) or conduit may be contaminated or blocked.

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9. Ensure Air Block is depressurized. Open air pressure relief valve by moving the blower pressure valve handle counter clockwise to the 9 o’clock position (Figure 44). Shut off the air from the compressor, decompress the air in the hose and disconnect the hose from the blower. 10. Remove Seal Disk and install Venturi (Figure 45). Use the provided 2.5 mm hex wrench.

Figure 44. Decompress Air Block

Figure 45. Install Venturi

NOTE: The venturi with the groove goes into the bottom and gets screwed into place while the top half has the protrusions and sets into the groove (Figure 46).

Figure 46. Install Venturi Bottom and Attach with Screw

24 5 Blue Heron Drive

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Prepare Cable The Deluxe LW Blower is designed so cable may be installed from the side. Follow these steps so cable is properly positioned to begin operation. 1. Choose the correct Cable Grip and install on fiber optic cable (Figure 47) (See Tables 1 & 2, on page 18). 2. Install 5/8" (16 mm) Swivel on Cable Grip using the 3/32" hex wrench. Grip must be firmly secured to cable (Figure 48). The eye on the grip can be compressed to fit smaller diameter conduits. The eye of a new grip can be taped with electrical tape in order to make it narrower and travel more easily through the conduit.

9.

Figure 48. Install Swivel on Cable Grip

Figure 47. Install Cable Grip on Fiber Optic Cable

3. Choose the correct Carrier and install on Swivel (Figure 49). 4. Raise upper Tractor Drive Cover with turn crank (Figure 50). Open the rear cable guide roller by pulling out spring plunger and rotating the roller out (Figure 51).

Figure 50. Raise Tractor Drive with Turn Crank

Figure 49. Install Carrier

5. Tilt Blower forward (Figure 52). 5 Blue Heron Drive

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Figure 52. Tilt Blower

Figure 51. Open Rollers

6. Add lubricant to Conduit before Carrier: 1/2 quart/6000 feet (.5 liter/2 km) (Figure 53). 7. Feed Cable Assembly through the counter rollers by lifting the Counter Roller Bracket. Lock the Rear Cable Guide Roller into place, and feed the cable through the Tractor Feed. (Figure 54).

Figure 53. Add Lubricant before Cable Assembly

Figure 54. Feed Cable Assembly Through Blower

8. Push Cable Assembly, including entire Cable Grip, into Conduit. 9. Add lubricant to Conduit behind Cable Assembly: 1/2 quart/3000 feet (.5 liter/1 km) (Figure 55).

26 5 Blue Heron Drive

Figure 55. Add Lubricant Behind Cable Assembly Collegeville, PA 19426

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10. Choose the correct Cable Seals and install on cable. Grooved side of Cable Seal faces conduit. Place Cable Seals into Venturi, split side down (Figure 56). 11. Close Air Block Cover (Figure 57). Tighten spanner nuts securely, but do not over tighten. Use cross tightening procedure with the spanner wrench to completely secure.

Figure 57. Close Air Block Cover

Figure 56. Install Cable Seals

Final Set-Up 1. Lower Tractor Drive Cover with turn crank until the cover reaches the stopperbushing. The stopper-bushing will prevent the tractor cover from being clamped too tightly on the cable (Figure 58). 2. Level the height of Air Block’s Venturi Tube with Tractor Drive and the approximate center line of the cable (Figure 59). Tighten slide cap screws after adjustments are made using 5 mm allen wrench.

10.

Figure 59. Level Air Block With Tractor Drive

Figure 58. Lower Tractor Drive Cover With Turn Crank

3. Notify crew that preparations are complete and cable blowing is to begin. 5 Blue Heron Drive

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IMPORTANT: It is recommended that if a reel-tensioning unit is not being used, the cable reel should then be kept under control by a second operator who is required to wear proper safety equipment and maintain a proper distance from the cable. A. FINAL INSPECTION !CAUTION: Before placing the blower into operation, always perform a final inspection of all components used. 1. Check that the Cable Grip is attached to conduit on receiving end. 2. Notify crew that preparations are complete and cable blowing is to begin.

Blower Operating Instructions

11.

A. OBSERVER AT EXIT PIT Station an observer with a 2-way communication device, at the far end of the Conduit, where the Cable carrier will exit. B. CONNECT THE HYDRAULIC SYSTEMS (Figure 60) The Deluxe LW Blower’s hydraulic system uses quick-disconnect couplings. Keep all connections clean to avoid contamination and possible system failure. Use hose end caps (supplied). A contaminated hydraulic system will effect the operation of the cable blower and may invalidate your product warranty. Take caution in routing the hoses to prevent a tripping hazard. Follow these steps to connect the hydraulic components: 1. Attach the quick-disconnect couplings to the hydraulic power supply (Figure 61).

HYDRAULIC POWER SOURCE HYDRAULIC HOSES

INNERDUCT

DELUXE LW BLOWER

ELECTRICAL HOOK UP TO POWER SOURCE

FIBER OPTIC CABLE

CABLE REEL

OPERATOR

AIR HOSE AIR COMPRESSOR

Figure 61. Attach Hydraulic Hoses

Figure 60. Typical Set-Up

28 5 Blue Heron Drive

2. Start the hydraulic power unit and check all connections for leaks with a piece of cardboard. In cold weather, run hydraulic power supply until hydraulic oil warms up. Collegeville, PA 19426

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WARNING: Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards: • Tighten all connections before applying pressure. Relieve pressure before connecting or disconnecting hoses. • Check for leaks with a piece of cardboard. Do not use hands! • Do not exceed working pressure of hydraulic hoses. Visually inspect hoses regularly and replace if damaged. 3. Run the blower for approximately 1 minute to remove any trapped air and then stop the blower and hydraulic power source. C. SET UP THE ELECTRONIC COUNTER BOX 1. Install Electronic Counter Box on blower and secure with 1/4 turn fasteners (Figure 62). 2. Attach Power Cord and plug into 12 volt power supply (Figure 63). Take caution in routing the electrical cord to prevent a tripping hazard.

Figure 62. Install Electronic Counter Box

Figure 63. Attach Power Cord

Figure 64. Attach Sensor Plugs

Figure 65.Turn on Power Switch

3. Attach solenoid valve, front tractor sensor and rear counter sensor plugs (Figure 64). 5 Blue Heron Drive

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Figure 66. Switch Configuration 4. Switch Configuration & Function (Figure 66) A description of each of the switches and displays for the Deluxe LW Blower Electronic Counter Box appears below. Power: Turns counter box ON or OFF (Figure 65). Start: Starts the tractor drive and is lit when unit is running. Stop: Stops the tractor drive. Serves as selection button in set up mode. Speed Display: Shows cable speed in ft/min. or m/min. Distance Display: Shows cable travel distance in feet or meters. Total Display: Shows the total amount of cable the machine has installed during its lifetime in feet or meters. Also displays errors when they occur. Emergency Stop: Immediately stops tractor drive & removes hydraulic power from the machine. Traction Control: Determines if the blower’s tractor drive will stop when the slippage or speed parameters are exceeded. Press ON (LED light is lit) to activate the hydraulic bypass system and stop the blower’s tractor drive. Press OFF (LED is not lit) to disable the hydraulic bypass valve. Also serves as toggle button during set up mode. • Once activated, the traction control will stop the blower’s tractor drive if track speed goes below the minimum speed setting of 20 ft/min. (6 m/min.) for more than two seconds or, if the slippage allowance or the maximum speed of 300 ft/min. (91 m/min.) are exceeded. • If slippage or speed parameters are exceeded, the total distance display will show one of the following: “P-1” - slippage error “P-2” - minspeed error “P-3” - maxspeed error 30 5 Blue Heron Drive

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5. Set the counter box configuration • To enter the set up mode, press the start and traction control buttons down while turning on the power. Once in set up mode, press the traction control button to scroll through set up options. “Units” will be the first choice. Press the stop button to select feet or meters. After selection is made, shut off power and the selection will automatically be saved. • The unit type is displayed as FT/MIN, FEET and M/MIN, METERS. An indicator light will illuminate, indicating the selected measurement unit. • Press E-Stop at any time to immediately stop the Tractor Drive. 6. Turn on counter box power • Select the Traction Control required. Press the Traction Control button ON (LED light is lit) to activate. This stops the blower’s tractor drive if the slippage or speed parameters are exceeded. Press OFF (LED is not lit) to disable this function. D. OPERATION 1. Re-connect hose from air compressor and attach all safety clips. Start the Air Compressor and Hydraulic Power Supply. Refer to respective manufacturers operating instructions for these units. 2. Make sure Electronics are in a “start” mode. If the electronics will not go into “start” mode make sure that the “e-stop” button is not depressed. Introduce a small amount of air to the system in order to straighten out the cable carrier inside the conduit. Turn the hydraulics to the “on” position (Figure 67). Slowly rotate the flow control knob, counterclockwise to engage tractor drive and increase speed (Figure 68). Push cable 50 to 100 feet (15 to 30 m) into Conduit.

Figure 68. Rotate Hydraulic Flow Control Knob

Figure 67. Turn on Hydraulics

3. Slowly open the Air Control Valve to allow air flow to the Air Block by turning flow control handle clockwise to the 3 o’clock position so it is in line with the air compressor hose (Figure 69). 4. Maintain control of cable reel to ensure smooth, stable flow. Failure to do so may cause cable to unwind too quickly. Continue to control cable speed with the flow control knob. 5 Blue Heron Drive

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!WARNING: Never wrap line around your hand, arm, foot, or leg. Severe personal injury or death could result from entanglement. !CAUTION: Always wear protective equipment: hard hat, safety glasses, safety shoes and work gloves. 5. Turn Tractor Drive off immediately when the observer indicates the Cable Carrier has exited the Conduit (air pressure will decrease sharply). • The Tractor Drive will continue to travel unless the track speed goes below the minimum speed setting of 20 ft/min. (6 m/min.), exceeds the slippage allowance, or the maximum speed of 300 ft/min. (91 m/min.) is exceeded for more than 2 seconds. The “stop” button and the “e-stop” button will also stop the tractor drive. • Press start to allow Tractor Drive to resume. NOTE: If the Traction Control LED is not lit, the Tractor Drive will continue to operate regardless of the slippage and speed parameters. • If slippage or speed parameters are exceeded, the speed display and the distance display will show one of the following: “P-1” - slippage error “P-2” - minspeed error “P-3” - maxspeed error 6. Turn off compressed air flow to the Air Block (Figure 70).

Figure 70. Turn Off Air at the Air Block

Figure 69. Turn On Air

!WARNING: Air Block Assembly contains compressed air when blower is operated. Opening Air Block while under pressure may cause serious personal injury. Ensure blower is depressurized before removing Air Block cover. 7. Remove Cable Grip from receiving end of Conduit. 8. If electronics stop blower before Cable Carrier exits, restart blower, making sure speed is within minimum and maximum allowance. Also see Troubleshooting Guide. 32 5 Blue Heron Drive

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Tear Down Procedures !WARNING: Air Block Assembly contains compressed air when blower is operated. Opening Air Block while under pressure may cause serious personal injury. Ensure blower is depressurized before removing Air Block cover. A. REMOVE POWER FROM UNIT. 1. Turn off compressed air by closing the Air Control Valve at the blower (Figure 71). Shut off air at the compressor and decompress air hose. Depressurize the air block by turning the air control valve to the 9 o’clock position (Figure 72). Remove air hose when system is relieved of pressure.

12.

Figure 72. Decompress Air Block

Figure 71. Turn Off Air at the Air Block

2. Raise Tractor Drive Cover with turn crank (Figure 73). 3. Turn off Hydraulic Power Supply and disconnect hydraulic hoses (Figure 74). Keep all connections free of dirt and particles. Use hose end caps (supplied).

Figure 74. Turn Off Hydraulic Power

Figure 73. Raise Tractor Drive Cover 4. Disconnect electronic cords. 5 Blue Heron Drive

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!WARNING: Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Release pressure before disconnecting hoses. B. REMOVE CABLE FROM BLOWER. 1. Open Air Block Cover and remove Cable Seals (Figure 75). 2. Pull the Guide Roller Knob and move Rear Guide Roller into open position. Lift Counter Roller Knobs so rollers are clear of cable (Figure 76). Pull cable out from side of unit.

Figure 75. Remove Cable Seals

Figure 76. Open Rollers To Remove Cable

C. SEPARATE UNIT FROM CONDUIT. 1. Open Conduit Clamp. 2. Pull unit away from Conduit. 3. If repositioning the machine, the Deluxe LW Blower should not be parked on a slope in excess of 13°. It should not be parked on a side hill of more that 15°.

34 5 Blue Heron Drive

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Maintenance Procedure

Daily

Weekly

Monthly

60 Days

90 Days

X

X

X

X

X

Inspect hoses for cracks and leaks.

X

X

X

X

X

Inspect fasteners and screws.

X

X

X

X

X

Check Belt Tension. Replace if excess wear has occured.

X

X

X

X

X

Clean all assemblies and components thoroughly.

Grease rear top shell alignment posts using available grease zerks. Lubricate Tractor adjustment bolt with grease zerks located on adjustment handle. Oil Oilite bearings on the counter clamp with light machine oil.

13.

X X X

Figure 77. Maintenance Schedule CAUTION: Operators are not permitted to perform maintenance tasks unless Condux personnel or representatives have appropriately trained them. Disconnect the machine from its electrical, pneumatic, and hydraulic power sources before servicing. A. TRACK CLEANING AND TIGHTENING 1. Inspect track before and after each use. 2. Clean after each use, or when necessary. Remove the top assembly to clean thoroughly by: • Remove top capscrew with a 3 mm allen wrench and the flat washer on clamp adjustment screw. This will allow for the top track assembly to be unscrewed off the blower with the clamp adjustment (Reference Appendix K). • Pressure wash if necessary 3. To compensate for normal belt stretching, there is a rubber dampening bushing part number 08780028, which is lobed larger on one side than the other, located at the pivot position of the idler skid part number 08780105. It is in the smaller lobe position when it leaves the factory. If a tighter belt is needed, rotate the bushing so the skid presses against the larger lobe. Be sure to have both bushings in the same configuration before locking the skid back into position. If this is not enough, then new tracks must be purchased (Reference Appendix B & C). B. REPLACEMENT OF THE DRIVE BELT The drive belt needs to be replaced when the machine is unable to tractor drive the specified range of cable diameters. Only genuine spares should be used otherwise the machine may be unsafe and void warranty (Reference Appendix B & C). 1. Remove the 2 capscrews which hold the sled in place with a 3 mm T-handled allen wrench. This should allow the sled to rotate up. 5 Blue Heron Drive

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2. Remove the pivot shaft with an 8 mm allen wrench. 3. On the bottom drive, remove the 3 capscrews from the prox cover with a 2 mm allen wrench. 4. The bearing cap can be removed from both the top and bottom assembly using a 5 mm allen wrench. 5. At this point, the drive pulley can be removed straight out the same hole as the bearing cap and the belt can be removed. This sequence is reversed for the reassembly of the new belt with a key note, the dampening bushing must be rotated back to the smaller lobe position on the pivot shaft. NOTE: Become familiar with the Replacement and Wear Parts associated with the Deluxe LW Blower, they are listed in Appendix T pg. 59. Class 4.6

in-lbs

ft-lbs

Class 8.8

Class 10.9

Class 12.9

Metric Thread Size

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

3 3.5

4.4 8

6.2 9.7

n/a n/a

n/a n/a

n/a n/a

n/a n/a

15 23

19 31

4

10.6

13.3

n/a

n/a

n/a

n/a

34

45

5 6

16 27

21 36

41 70

55 93

59 100

78 133

69 117

91 156

7

45

60.5

117

156

167

223

195

260

8

66

87.5

169

226

240

324

288

372

10 12

11 19

15 25

28 49

37 65

40 70

53 92

47 81

62 108

14

30

40

105

103

111

148

129

173

16

47

62.5

125

167

173

231

202

269

18

65

86

172

230

238

317

249

371

20

91.5

122

243

325

338

450

395

526

22 24

125 158

166 210

332 420

443 562

459 583

612 778

536 682

715 909

27

232

308

617

822

853

1,138

997

1,330

30 33 36

314 428 550

419 570 732

838 1,140 1,464

1,117 1,520 1,952

1,160 1,577 2,025

1,545 2,103 2,701

1,355 1,844 2,368

1,807 2,458 3,156

Figure 78. Torque Specifications for Steel into Steel Class 4.6

in-lbs

ft-lbs

36 5 Blue Heron Drive

Class 8.8

Class 10.9

Class 12.9

Metric Thread Size

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

3

2.64

3.72

n/a

n/a

n/a

n/a

9

11.4

3.5

4.8

5.82

n/a

n/a

n/a

n/a

13.8

18.6

4 5

6.36 9.6

7.98 12.6

n/a 24.6

n/a 33

n/a 35.4

n/a 46.8

20.4 41.4

27 54.6

6

16.2

21.6

42

55.8

60

79.8

70.2

93.6

7 8

27 39.6

36.3 52.5

70.2 101.4

93.6 135.6

100.2 144

133.8 194.4

117 172.8

156 223.2

10

6.6

9

16.8

22.2

24

31.8

28.2

37.2

12 14

11.4 18

15 24

29.4 63

39 61.8

42 66.6

55.2 88.8

48.6 77.4

64.8 103.8

16

28.2

37.5

75

100.2

103.8

138.6

121.2

161.4

18 20

39 54.9

51.6 73.2

103.2 145.8

138 195

142.8 202.8

190.2 270

149.4 237

222.6 315.6

22

75

99.6

199.2

265.8

275.4

367.2

321.6

429

24

94.8

126

252

337.2

349.8

466.8

409.2

545.4

27 30

139.2 188.4

184.8 251.4

370.2 502.8

493.2 670.2

511.8 696

682.8 927

598.2 813

798 1084.2

33 36

256.8 330

342 439.2

684 878.4

912 1171.2

946.2 1215

1261.8 1620.6

1106.4 1420.8

1474.8 1893.6

Figure 79. Torque Specifications for Steel Capscrew into Aluminum

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Troubleshooting Guide Problem

Solution

Cable becomes jammed in the conduit system.

1. Inform the people at the other end of the conduit that a problem has been experienced and the operator is going to shut down the system.

14.

2. Shut off the hydraulic valve at the blower. 3. Shut off the pneumatic air supply with the Air Control Valve turning it to the 9 o’clock position, allowing the air pressure to be depressurized from the conduit and the air block. 3. Using the counter or the measurement on the cable, determine where the blockage might be located. 5. Notify supervisor about problem and determine a solution accordingly. Tractor Feed does not pull the cable off the reel.

Assist the reel by pushing it, and/or by pulling the cable off the reel.

Blower cuts out with electronic error of minspeed or highspeed error.

Blower has exceeded the minimum or maximum speed allowance. Adjust speed accordingly, or wipe cable clean from mud and dirt.

It is difficult to keep the cable moving near the end of the conduit run.

Assist the blower by manually pushing the cable into the conduit. Do not bend or crimp the cable.

The cable run is hard to restart after having stopped.

Put air to the system with the track down. The tractor feed can be restarted after the air pressure has increased and stabilized.

Tractor feed doesn’t start.

1. Hydraulic flow control is at the lowest speed-increase flow speed slowly. 2. Hydraulic “on”/”off” is in the “off” position-rotate handle to the “on” position. 3. Electronics is in the “stop” position-push the “start” button. 4. “E-stop” is still in the active mode-rotate clockwise to allow the button to reset. 5. Hydraulic power pack is in the “off” position-turn it to the “on” position. 6. Check that the hydraulic hoses are connected correctly.

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

37

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

5 Blue Heron Drive

www.comstarsupply.com

Collegeville, PA 19426

38 (610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Blower with Job Box

A. APPENDIX

Blower with Job Box

ITEM 1

PART NO. 02288701

DESCRIPTION HITCH PIN, 3/8 X 4 1/2

2 3

08780195 08782000

CART, JOB BOX LW FO BLOWER-ASSY LW FIBER OPTIC BLOWER-DELUXE

QTY 1 1 1

Parts List, Blower with Job Box 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

39

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Upper Drive Shaft Kit

B. APPENDIX

Upper Drive Shaft Repair Kit 08780625

ITEM 1 2 3 5

PART NO. 02288583 02288656 02288708 08780010

DESCRIPTION CAPSRW M06-1.0X 10 BHSS 18-8 RING,RETAINING 28MM EXTERNAL PULLEY,TIMING-DRV 50MM-18T-54 CAP,BEARING ASSY-UPPER DRVSHFT

QTY 2 1 1 1

6 9

08780011 08780181

SHAFT,UPPER DRIVE-UPR DRV ASSY KEY,DRIVE SHAFT 7MM-8MM-19.5MM

1 1

Parts List, Upper Drive Shaft Replacement Kit 08780625

ITEM 4 7 8

PART NO. 08780904 08780029 08780105

DESCRIPTION BELT,CABLE 50MM X 260MM CENTER SHAFT,PIVOT-IDLER ASSY BRACKET,IDLER ROLLER MNT ASSY

QTY 1 1 1

Upper Drive Shaft Individual Replacement Parts 40 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Lower Drive Shaft Kit

C. APPENDIX

Lower Drive Shaft Replacement Kit 08780626

ITEM 1 2 3 7

PART NO. 02288583 02288656 02288708 08780181

DESCRIPTION CAPSRW M06-1.0X 10 BHSS 18-8 RING,RETAINING 28MM EXTERNAL PULLEY,TIMING-DRV 50MM-18T-54 KEY,DRIVE SHAFT 7MM-8MM-19.5MM

8 9

08780277 08780278

SHAFT,LOWER DRIVE-LWR DRV ASSY CAP,BEARING ASSY-LOWER DRVSHFT

QTY 2 1 1 1 1 1

Parts List, Lower Drive Shaft Replacement Kit 08780626

ITEM 4 5 6

PART NO. 08780904 08780029 08780105

DESCRIPTION BELT,CABLE 50MM X 260MM CENTER SHAFT,PIVOT-IDLER ASSY BRACKET,IDLER ROLLER MNT ASSY

QTY 1 1 1

Lower Drive Shaft Individual Replacement Parts 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

41

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Hydraulic Motor Kit

D. APPENDIX

Hydraulic Motor Replacement Kit 08780636

ITEM 1

PART NO. 02288584

DESCRIPTION CAPSRW M06-1.0X 20 CSSS 18-8

QTY 3

2 3 4

02288642 02288702 08780163

FTG,HYD 06-JIC; 3/8 BSP_M SEAL,BONDED 3/8 BRITISH THDS MOTOR,HYD (PAINTED)-LW BLWR

2 2 1

Parts List, Hydraulic Motor Replacement Kit 08780636

42 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Idler Bracket Bushing & Screw Kits

E. APPENDIX

Idler Bracket Bushing Replacement Kit 08780642

Idler Bracket Screw Replacement Kit 08780643

ITEM 1

PART NO. 08780028

DESCRIPTION BUSHING,DAMPENING-POLYURETHANE

QTY 2

Parts List, Idler Bracket Bushing Replacement Kit 08780642

ITEM 1

PART NO. 08780194

DESCRIPTION SCREW,IDLER RETAINER SLIDE

QTY 2

Parts List, Idler Bracket Screw Replacement Kit 08780643 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

43

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Air Block Assembly Kits

F. APPENDIX

Airblock Bracket Replacement Kit 08780629

44 5 Blue Heron Drive

Airblock Clamp Assembly Replacement Kit 08780627

Airblock Assembly Replacement Kit 08780628 Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

ITEM 2

PART NO. 02288573

DESCRIPTION CAPSRW M05-0.8X 16 CSSS 18-8

3 4 8 9

02288605 02288606 08780159 08780258

SCREW,SHOULDER M10 DIA- 16MMLG FLATWSHR M10-NARR ST CZ MOUNT,AIRBLOCK(W/INSERT)LW FOB PAD,GUIDE-LW AIRBLOCK MOUNT

QTY 8 2 2 1 2

Parts List, Airblock Bracket Replacement Kit 08780629 ITEM

PART NO.

DESCRIPTION

QTY

1 2

02129701 02288573

UNIVERSAL CPLG, 3/4 MALE CAPSRW M05-0.8X 16 CSSS 18-8

1 1

5

02288671

MUFFLER,PNEUMATIC EXHAUST 12MP

1

6 7

08780071 08780073

BLOCK,CLAMP(ASSY) LW FO BLOWER AIRBLOCK (ASSY) LW FO BLOWER

1 1

Airblock Bracket Individual Replacement Parts

ITEM 1 2

PART NO. 02288588 02288665

DESCRIPTION FLATWSHR M06-NARR ST C NUT M06-1.00 NYLOC ST GR2 CZ

3 4 5

08780070 08780166 08780167

SHAFT,PIVOT-CLAMP BLOCK-LW BLR NUT,KNURLED-CLAMP/AIR BLOCK-LW BOLT,CLAMP-CLAMP/AIR BLOCK-LW

QTY 1 1 1 1 1

Parts List, Airblock Clamp Assembly Replacement Kit 08780627

ITEM 2

PART NO. 02288588

DESCRIPTION FLATWSHR M06-NARR ST C

QTY 2

3 4

02288665 08780062

NUT M06-1.00 NYLOC ST GR2 CZ SHAFT,PIVOT-AIRBLOCK-LW FOB

2 1

5 6

08780166 08780167

NUT,KNURLED-CLAMP/AIR BLOCK-LW BOLT,CLAMP-CLAMP/AIR BLOCK-LW

2 2

Parts List, Airblock Assembly Replacement Kit 08780628

ITEM 1

PART NO. 02288582

DESCRIPTION GAUGE,PRESS 0-200 1.50 BACK MT

QTY 1

Airblock Assembly Individual Replacement Parts 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

45

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Counter Clamp Roller & Cable Guide Kits

G. APPENDIX

Counter Clamp Roller Replacement Kit 08780630 ITEM

PART NO.

DESCRIPTION

1 2 3 4

08780091 08780094 08780095 08780096

ROLLER,CABLE CLAMP-ASSY SHAFT,CABLE CLAMP ROLLER SPACER,10MM-14MM-21.5MM NYLON SPACER,10MM- 14MM- 1.5MM NYLON

QTY 1 1 1 1

Parts List, Counter Clamp Roller Replacement Kit 08780630

Counter Cable Guide Replacement Kit 08780631 ITEM 1 2 46 5 Blue Heron Drive

PART NO. 02288649 08780266

DESCRIPTION CAPSRW M03-0.5X 12 SHSS 18-8 GUIDE,CABLE-UPPER ENTRANCE

QTY 2 1

Parts List, Counter Cable Guide Replacement Kit 08780631

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Timing & Takeup Roller & Idler Roller Kits

H. APPENDIX

Timing & Takeup Roller Replacement Kit 08780632 ITEM 1 2 3 4

PART NO. 02288573 08780006 08780037 08780249

DESCRIPTION CAPSRW M05-0.8X 16 CSSS 18-8 SHAFT,IDLER PULLEY-BT BLOWER RETAINER,IDLR PLLY-12MM SHAFT PULLEY,TIMING IDLER ASSY-54MM

QTY 1 1 1 1

Parts List, Timing & Takeup Roller Replacement Kit 08780632

Idler Roller Replacement Kit 08780633

ITEM 1 2 3 4

5 Blue Heron Drive

PART NO. 02288573 08780007 08780031 08780250

DESCRIPTION CAPSRW M05-0.8X 16 CSSS 18-8 SHAFT,IDLER ROLLER-LW BLOWER RETAINER,IDLER ROLL-10MM SHAFT PULLEY,IDLER ASSY-54MM

Parts List, Idler Roller Replacement Kit 08780633

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

QTY 1 1 1 1 47

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Hydraulic Coupler (Male) Kit

I. APPENDIX

Hydraulic Coupler (Male) Replacement Kit 08780634 ITEM 1 7 12

PART NO. 02260200 02288620 02288703

DESCRIPTION CAP,DUST(MALE FLAT FACE CPLRS) COUPLER,MALE-FLAT FACE METRIC SEAL,BONDED 18MM THREADS

QTY 1 1 1

Parts List, Hydraulic Coupler (Male) Replacement Kit 08780634 ITEM 2 3 4 5 6 8 9 10 11 13 48 5 Blue Heron Drive

PART NO. 02269719 02269708 02286710 02288589 02288590 02288637 02288641 02288643 02288643 02288859

DESCRIPTION VALVE,CARTRIDGE-RELIEF VALVE,CARTRIDGE-DIREC. CONTROL HOSE 06 X 22.00-06SW-06SW 3000 VALVE,CARTRIDGE-FLOW CONTROL KNOB,CARTRIDGE VALVE FLOW CTRL GAUGE,PRESS 0-2000 1.50 BCK MT LEVER,BALL HANDLE 2 POS DETENT HOSE 06 X 21.00-06SW-06SW 3000 HOSE 06 X 21.00-06SW-06SW 3000 VALVE,CARTRIDGE-SOLENOID 12VLT

QTY 1 1 1 1 1 1 1 1 1 1

Hydraulic Coupler (Male) Individual Replacement Parts Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Hydraulic Coupler (Female) Kit

J. APPENDIX

Hydraulic Coupler (Female) Replacement Kit 08780635 ITEM 1 7 12

PART NO. 02260200 02288619 02288703

DESCRIPTION CAP,DUST(FEMALE FLAT FACE CPLRS) COUPLER,FEMALE-FLT FACE METRIC SEAL,BONDED 18MM THREADS

QTY 1 1 1

Parts List, Hydraulic Coupler (Female) Replacement Kit 08780635 ITEM

PART NO.

DESCRIPTION

2 3

02269719 02269708

VALVE,CARTRIDGE-RELIEF VALVE,CARTRIDGE-DIREC. CONTROL

1 1

4 5 6

02286710 02288589 02288590

HOSE 06 X 22.00-06SW-06SW 3000 VALVE,CARTRIDGE-FLOW CONTROL KNOB,CARTRIDGE VALVE FLOW CTRL

1 1 1

8 9

02288637 02288641

GAUGE,PRESS 0-2000 1.50 BCK MT LEVER,BALL HANDLE 2 POS DETENT

1 1

10 11 13

02288643 02288643 02288859

HOSE 06 X 21.00-06SW-06SW 3000 HOSE 06 X 21.00-06SW-06SW 3000 VALVE,CARTRIDGE-SOLENOID 12VLT

1 1 1

5 Blue Heron Drive

QTY

Hydraulic Coupler (Female) Individual Replacement Parts Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

49

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Clamp Adjustment Kit

K. APPENDIX

Clamp Adjustment Replacement Kit 08780637 ITEM 2 3 5 6 8

PART NO. 02288644 02288646 08780081 08780106 08780280

DESCRIPTION LEVER, BALL KNOB 10MM 08MM THR ZERK,GREASE, 6MM-1.0 STRAIGHT SHAFT,TENSION ADJUSTMENT BODY,HANDLE-CLAMP CYLINDER WASHER,THRST 22.2MM-45MM-1.5MM

QTY 2 1 1 1 1

Parts List, Clamp Adjustment Replacement Kit 08780637

ITEM 1

PART NO. 02288610

DESCRIPTION CYLINDER,LIFT-PNUEMATIC CHRGD

QTY 1

Clamp Adjustment Individual Replacement Parts 50 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Lower Counter Roller Kit

L. APPENDIX

Lower Counter Roller Replacement Kit 08780638 ITEM

PART NO.

DESCRIPTION

1 2 3 4

02288574 08780022 08780257 08780260

CAPSRW M05-0.8X 12 BHSS 18-8 SHAFT,COUNTER(ASSY)LW FO BLWR HOUSING,BRG ASSY-(FRONT) HOUSING,BEARING ASSY-CNTR RLLR

QTY 4 1 1 1

Parts List, Lower Counter Roller Replacement Kit 08780638

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

51

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

RH Cable Guide Roller Kit & Adjustable Rear Cable Guide Kit

M. APPENDIX

ITEM

PART NO.

DESCRIPTION

2 3 7

02288574 02288584 08780133

CAPSRW M05-0.8X 12 BHSS 18-8 CAPSRW M06-1.0X 20 CSSS 18-8 ROLLER,REAR ENTRY(ASSY)

QTY 1 2 1

9 10

08780136 08780252

RETAINER,REAR ENTRY ROLLER SHAFT,VERT GUIDE ROLLER

1 1

Parts List, RH Cable Guide Roller Replacement Kit 08780639 ITEM 1 3 4 5 6 8 11 12 13 14 15 16 17 18 52

5 Blue Heron Drive

PART NO. 02288574 02288584 08780133 08780136 08780252 02288574 02288584 08780133 08780136 02288574 02288584 08780133 08780136 02288574

DESCRIPTION NUT M5-0.80 NYLOC CAPSRW M06-1.0X 20 CSSS 18-8 SHOULDER SCREW M06-35MM CAPSRW M04-0.7X 10 CSSS 18-8 SETSCREW M04-0.7X 10 HX 50 GUIDE PAD-REAR CABLE ENTRY PIVOT ARM-RH PIVOT ARM-LH ADJUSTMENT SHAFT PIVOT PIN-RH PIVOT PIN-LH BEARING PLATE ASSY PIVOT ARM ADJ. KNOB PIVOT MOUNT BLOCK ASSY

QTY 1 3 2 4 2 1 1 1 1 1 1 2 1 1

Parts List, Adjustable Rear Cable Guide Replacement Kit 08780482 Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

LH Cable Guide Roller Kit

N. APPENDIX

LH Cable Guide Roller Replacement Kit 08780640

ITEM 1 2 3

PART NO. 02288574 02288579 02288585

DESCRIPTION CAPSRW M05-0.8X 12 BHSS 18-8 PLUNGER,SPRING-M10X1.5 SS SCREW,SHOULDER M08 DIA- 16MMLG

4 5 6

08780059 08780133 08780136

SHAFT,PIVOT GUIDE ROLLER ROLLER,REAR ENTRY(ASSY) RETAINER,REAR ENTRY ROLLER

QTY 1 1 1 1 1 1

Parts List, LH Cable Guide Roller Replacement Kit 08780640

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

53

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Counter Spring Kit

O. APPENDIX

Counter Spring Replacement Kit 08780641 ITEM 1

PART NO. 02288583

DESCRIPTION CAPSRW M06-1.0X 10 BHSS 18-8

2 3 6 10

02288588 02288639 02288721 08780097

FLATWSHR M06-NARR ST C CAP,VINYL .75ID-.88OD-1.00 BLK SPRING,COMPRSS .063-0.600-2.50 RETAINER,SPRING-CABLE CLAMP

QTY 1 1 1 1 1

Parts List, Counter Spring Replacement Kit 08780641 ITEM 4 5

PART NO. 02288677 02288680

DESCRIPTION SENSOR,PICKUP-TURCK PICOPROX CORDSET,4PIN-90DEG/90DEG 400MM

QTY 1 1

7 8 9 11 12 13

02288727 08780022 08780090 08780113 08780135 08780193

CORDSET,4PIN-STRT/90DEG 600MM SHAFT,COUNTER(ASSY)LW FO BLWR CLAMP,CABLE COUNTER-ASSY COUNTER ASSEMBLY, W/LABELS PAD,GUIDE-REAR CABLE ENTRY CORDSET ASSY 2PIN W/CONNECTORS

1 1 1 1 1 1

54 5 Blue Heron Drive

Counter Spring Individual Replacement Parts Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Base Mount

P. APPENDIX

ITEM 1 2 3

PART NO. 02288654 02288701 08780160

DESCRIPTION HANDLE,ADJUSTABLE CLAMPING PIN,HITCH COTTERLESS 3/8 X4.50 BASE,ADJSTBLE ASSY-LW FO BLWR

QTY 1 1 1

Base Mount Individual Replacement Parts

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

55

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Pneumatic & Electrical Circuits

Q. APPENDIX

Pneumatic Circuit 08780994

56 5 Blue Heron Drive

Electrical Circuit 08780996 Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Hydraulic Circuit

R. APPENDIX

Hydraulic Circuit 08780997

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

57

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Suggested Hydraulic Lubricants

S. APPENDIX

Table of suggested hydraulic lubricants to use on the Fiber Blowing machine. The use of lubricants not in conformity with the technical specifications indicated in the present manual could seriously damage the machine components and consequently the warranty conditions are not valid. Life expectancy of the machine can only be assured if the recommended lubricants are used. SUGGESTED HYDRAULIC FLUIDS AND GREASE Type Hydraulic Fluid

Grease

Chevron Exxon Mobil Gulf Shell Texaco Union AMSOIL Sunvis

Duralith EP 2 Mobilux EP 2 Crown EP 2 Supergrease EP 2 Multifak EP 2 -

“Clarity” AW ISO 32 “Univis” J32 D.T.E. 13M “Harmony” AW-HVI-150-32 “Tellus T” 32 “Rando” HDZ 32 “Unax” AW-WR-32 AWH ISO 32 Low Pour H/O 32 - Product code 193000

SUMMARY OF SELECT PNEUMATIC AND HYDRAULIC COMPONENTS Hydraulic Quick Disconnect, Condux International P/N 02260000 information: FASTER PART NUMBER 2FFN38-12NPT-F 1/2" FEMALE NPT THREAD Hydraulic Quick Disconnect, Condux International P/N 02260100 information: FASTER PART NUMBER 2FFN38-12NPT-M 1/2" MALE NPT THREAD Solenoid Valve, Condux International P/N 02288859 information: HYDRAFORCE P/N: SV10-24-0-N-12-DS Hydraulic Motor, Condux International P/N 02288562 information: DANFOSS P/N 151G0006 Air Coupling, Condux International P/N 02129701 information: DIXON PART NUMBER AM7 Gas Cylinder, Condux International P/N 02288610 information: BANSBACH P/N: E0C1ZDB-38-208/1340N Pneumatic Valve, Condux International P/N 02288671 information: POLYCONN P/N: PCMFL-12 SILENCER Air Gun Hose Assembly, Condux International P/N 08780908 58 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Possible Wear & Replacement Parts For replacement parts please contact the factory or Condux representative. List of possible wear items: Description Belt, Cable 50MM X 260MM Center Cable Seals Kit, Seal Replacement-LW Blower Machine Screws,M04-0.7X16 (10) Pad, Guide-Rear Cable Entry Guide, Cable-Upper Entrance Rear Entry Rollers Upper Counter Roller Lower Counter Roller Carrier Seals

Part Number 08780904 See Table 1, pg 18 for correct cable seal size 08780126 08780424 08780135 08780266 08780135 08780091 08780022 See Table 2, pg 18 for correct carrier size

T. APPENDIX

PACKAGE ADD-ONS 08780393 CABLE PACK 0.23"-0.34" (5.8-8.6 mm) CABLE-LW 08780394 08780395

CABLE PACK 0.35"-0.60" (8.9-15.2 mm) CABLE-LW CABLE PACK 0.61"-0.85" (15.3-21.6 mm) CABLE-LW

08780396

CABLE PACK 0.86"-1.05" (21.7-26.7 mm) CABLE-LW

08780240 08780385 08780389

DUCT PACK 1.00" DUCT OD SDR 13.5/ SDR 11 DUCT PACK 1.25" DUCT OD SDR 13.5/ SDR 11 DUCT PACK 1.50" DUCT OD SDR 13.5/ SDR 11

08780386

DUCT PACK 33.4MM (1.315) DUCT OD LW

08780387 08780388

DUCT PACK 36.0MM (1.417) DUCT OD LW DUCT PACK 37.0MM (1.457) DUCT OD LW

08780389

DUCT PACK 38.1MM (1.500) DUCT OD LW

08780390 08780391

DUCT PACK 40.0MM (1.575) DUCT OD LW DUCT PACK 42.0MM (1.653) DUCT OD LW

08780392 08780397 08780545 08780575

DUCT PACK 42.2MM (1.660) DUCT OD LW DUCT PACK 48.3MM (1.900) DUCT OD LW DUCT PACK 44.0MM (1.732) DUCT OD LW DUCT PACK 50.0MM (1.968) DUCT OD LW

OTHER WEAR OR REPLACEMENT PARTS 08780126 KIT,SEAL REPLACEMENT-LW BLOWER 08780223 08761248 08761249 02286416 08780904

PLUG,VENTURI AIR-LW FO BLOWER CORD,POWER ASSY W/LIGHTER PLUG CORD,POWER-BLOWR W/BENDIX PLUG CORD,EXTENSION-2PIN STRGHT 20' BELT,CABLE 50MM X 260MM CENTER

08780135 08780266 08780133 08780091 08780022

PAD,GUIDE-REAR CABLE ENTRY GUIDE,CABLE-UPPER ENTRANCE ROLLER,REAR ENTRY(ASSY) ROLLER,CABLE CLAMP-ASSY SHAFT,COUNTER(ASSY)LW FO BLWR

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

59

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Replacement Parts & Accessories CABLE PACK WEAR PARTS 08780406 1 SEAL,CABLE 0.23-0.28 (5.8-7.3 mm) OD CABLE 08780407 1 SEAL,CABLE 0.29-0.34 (7.4-8.8 mm) OD CABLE 08761424 08761425 08761426

2 2 2

SEAL,CABLE 0.35-0.42 (8.9-10.7 mm) OD CABLE SEAL,CABLE 0.43-0.48 (10.8-12.2 mm) OD CABLE SEAL,CABLE 0.49-0.55 (12.3-14.0 mm) OD CABLE

08761427 08761428 08761429 08761430 08761431

2 3 3 3 3

SEAL,CABLE SEAL,CABLE SEAL,CABLE SEAL,CABLE SEAL,CABLE

08761432

4

SEAL,CABLE 0.86-0.92 (21.7-23.4 mm) OD CABLE

08761433 08761434

4 4

SEAL,CABLE 0.93-0.97 (23.5-24.6 mm) OD CABLE SEAL,CABLE 0.98-1.04 (24.7-26.4 mm) OD CABLE

08761435 08780424

4

SEAL,CABLE 1.05-1.13 (26.5-28.7 mm) OD CABLE MACHINE SCREWS,M04-0.7X16 (10)

08643754 08643755 08643756

1 2 2

CABLE GRIP- .21- .35-14 1400# CABLE GRIP- .32- .48-19 2000# CABLE GRIP- .42- .61-21 2500#

08643757 08643758 08643759

3 3 4

CABLE GRIP- .53- .74-23 3000# CABLE GRIP- .64- .87-25 4200# CABLE GRIP- .75-1.00-28 4200#

08643137

4

CABLE GRIP-1.00-1.24-20 6800#

0.56-0.60 0.61-0.67 0.68-0.73 0.74-0.79 0.80-0.85

(14.1-15.2 (15.3-17.0 (17.1-18.5 (18.6-20.1 (20.2-21.6

mm) mm) mm) mm) mm)

OD OD OD OD OD

CABLE CABLE CABLE CABLE CABLE

Note 1 - Included in Cable Pack 0.23-0.34 Cable-LW Note 2 - Included in Cable Pack 0.35-0.60 Cable-LW Note 3 - Included in Cable Pack 0.61-0.85 Cable-LW Note 4 - Included in Cable Pack 0.86-1.05 Cable-LW BLOWING LUBRICANT 08230600 LUBRICANT, POLY PL2K 1 QT 12/C EA 08230601 08230900 08230901 08230700

60 5 Blue Heron Drive

LUBRICANT, POLY PL2K 1 GL 4/C EA LUBRICANT, POLY WPL2K 1 QT 12/C EA LUBRICANT, POLY WPL2K 1 GL 4/C EA LUBRICANT, CABLE EASE 1 QT 12/C EA

MANUALS 08780998 08780999

MANUAL, QUICK REF LW FO BLOWER MANUAL, LW FO CABLE BLOWER

TOOLS 02288787 02288662 02283800 02289261

DRIVER, HEX BALL-POINT 2.5MM WRENCH, SPANNER .187 PIN/1.00 D DRIVER, HEX BALL 3/32 INCH WRENCH, ALLEN 5MM

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Replacement Parts & Accessories DUCT PACK WEAR PARTS 08761439 CARRIERS,FOAM 1-1/4 OD 08761440 CARRIERS,FOAM 1-1/2 OD 08761441 CARRIERS,FOAM 1-3/4 OD 08761442 CARRIERS,FOAM 2 OD 08780230 CARRIER ASSY-0.787 (20.0MM) OD 08780235 DISC,CARRIER-20MM CARRIER 08761715 CARRIER ASSY-0.906 (23.0MM) OD 08761716 DISC,CARRIER-0.906 (23.0MM) OD 08761810 CARRIER ASSY-1.063 (27.0MM) OD 08031882 CONE,RUBBER-27.0MM DIAM 08761811 CARRIER ASSY-1.121 (28.5MM) OD 08031883 CONE,RUBBER-28.5MM DIAM 08761812 CARRIER ASSY-1.181 (30.0MM) OD 08031884 CONE,RUBBER-30.0MM DIAM 08761813 CARRIER ASSY-1.220 (31.0MM) OD 08031885 CONE,RUBBER-31.0MM DIAM 08761814 CARRIER ASSY-1.250 (31.7MM) OD 08031886 CONE,RUBBER-31.7MM DIAM 08761815 CARRIER ASSY-1.300 (33.0MM) OD 08031887 CONE,RUBBER-33.0MM DIAM 08761816 CARRIER ASSY-1.378 (35.0MM) OD 08031888 CONE,RUBBER-35.0MM DIAM 08761817 CARRIER ASSY-1.414 (35.9MM) OD 08031889 CONE,RUBBER-35.9MM DIAM 08761822 CARRIER ASSY-1.496 (38.0MM) OD 08031905 CONE,RUBBER-38.0MM DIAM 08761818 CARRIER ASSY-1.606 (40.8MM) OD 08031890 CONE,RUBBER-40.8MM DIAM 08761819 CARRIER ASSY-1.618 (41.1MM) OD 08031891 CONE,RUBBER-41.1MM DIAM 08761824 CARRIER ASSY-1.969 (50.0MM) OD 08031907 CONE,RUBBER-50.0MM DIAM 08761820 CARRIER ASSY-2.023 (51.4MM) OD 08031892 CONE,RUBBER-51.4MM DIAM 08761821 CARRIER ASSY-2.047 (52.0MM) OD 08031893 CONE,RUBBER-52.0MM DIAM 08761823 CARRIER ASSY-2.142 (54.4MM) OD 08031906 CONE,RUBBER-54.4MM DIAM 08643210 CABLE GRIP-.19-.24-4.3 400# 08643213 CABLE GRIP-.25-.36-4.3 450# 08643216 CABLE GRIP-.37-.49-7 900# 08643122 CABLE GRIP-.50-.61-16 2800# 08643128 CABLE GRIP-.62-.74-16 2800# 08643131 CABLE GRIP-.75-.99-20 4000# 08643137 CABLE GRIP-1.00-1.24-20 6800# 08643143 CABLE GRIP-1.25-1.49-21 6800# 08643149 CABLE GRIP-1.50-1.99-23 6800# DUCT COUPLER CLAMP 08676844 CLAMP,INNERDUCT COUPLER-ASSY 08676826 COUPLING,SPLIT 1.50"/2.00" 08676859 COUPLING,INSRT-1" DCT 1.315 W/S 08676860 COUPLING,INSRT-1.25" DCT 1.66 W/S 08676861 COUPLING, INSRT-1.5" DCT 1.90 W/S 08676862 COUPLING, INSRT-2" DCT 2.37 W/S 08676863 COUPLING, INSERT-40MM DUCT W/S 08676864 COUPLING, INSERT-46MM DUCT W/S 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

61

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Replacement Parts & Accessories FIXED HEAD INNERDUCT PULLING EYE Tapered buttress threads thread into the innerduct for maximum pulling strength. These eyes connect directly to a Condux swivel. When properly sized and installed, these eyes will not pull out of the innerduct until the pulling tensions have greatly exceeded the maximum pulling tensions recommended by the innerduct manufacturers. NOTE: To determine correct pulling eye size, obtain the actual innerduct inside diameter (I.D.). The I.D. measurement must be greater than dimension A and smaller than dimension B.

F

A

D

Part Number 08913400 08913401 08913402 08913403 08913404

62 5 Blue Heron Drive

Innerduct Range (in) SDR 3 ⁄4 7-15 1 1-1 ⁄8 7-15 11⁄4 9-15 9-15 11⁄2 2 9-15

B

Innerduct I.D. Range A–B (in) A–B (mm) .71-.87 18-22 .88-1.20 22-30 1.21-1.41 31-36 1.42-1.62 36-41 1.78-2.03 45-52

Collegeville, PA 19426

C

Max O.D. C (in) (mm) 1.25 32 1.50 38 1.75 44 2.00 51 2.50 64

(610) 831-5020

www.comstarsupply.com

E

Hole Dia. D (in) (mm) .25 6 .38 10 .38 10 .38 10 .38 10

Eye Dia. E (in) (mm) .50 13 .50 13 .50 13 .50 13 .50 13

Thickness F (in) (mm) .45 10 .45 10 .45 10 .45 10 .45 10

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

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Replacement Parts & Accessories CABLE JACKET SLITTER This popular tool makes quick, safe work of removing sheath and turnplate from communication cables. With a turn of the handle, the toothed wheel pulls the tool forward while the angled blade makes a clean cut. Blade guard protects conductors from damage. Also excellent for slitting innerduct. Minimum cable diameter 1" (25 mm). Part Number 08012900 08012901

Description Cable Jacket Slitter Replacement Blade

INNERDUCT SLITTER The Innerduct Slitter is designed for fast, safe cutting of innerducts from 1" (25 mm) to 2" (51 mm) OD. Part Number 08013100 08013101

Description Innerduct Slitter Replacement Blade

PVC & POLYETHYLENE CUTTER Razor sharp cutting blade makes a fast, clean, burr-free cut in PVC and polyethylene. Ratcheting handle provides for sure, steady cutting action. Reduces cutting and preparation time. Part Number 08948050 08948060 08948051 08948061

5 Blue Heron Drive

Description Small diameter—up to 11⁄4" (32 mm) conduit with 11⁄2" (38 mm) O.D. Large diameter—up to 2" (51 mm) conduit with 23⁄8" (60 mm) O.D. Replacement Blade for Small Cutter Replacement Blade for Large Cutter

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

63

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Replacement Parts & Accessories INNERDUCT PRESSURE TEST KIT Use the Innerduct Pressure Test Kit to pressure test innerduct before setting up the Deluxe LW Blower. The conduit system must be able to withstand and hold 150 psi (10.3 bar) for the Cable Blower to work properly. Part Number 08761457

Description Pressure Test Kit for 1", 11⁄4" & 11⁄2" SDR 11 & 13.5 Innerduct • Control Valve Assembly • Seal-Off Heads • Pulling Eyes • Pulling Grips • Tool Box Other Components Available Part Number Description 08034318 Seal-Off Head for 2.00" SDR 11 & 13.5 Innerduct 08913328 Pulling Eye for 2.00" SDR 11 & 13.5 Innerduct 08643155 Pulling Grip for 2.00" SDR 11 & 13.5 Innerduct

POLYWATER® PRELUBE 2000™ Specially formulated for use with fiber optic cable blowing systems, Polywater® Prelube 2000™ has been field proven with the Deluxe LW Blower. This lubricant is a special lubricant used to prelubricate the conduit system before installing the cable. Prelube 2000 is compatible with all types of cable jackets and conduit types. Part Number 08230600 08230601 08230900 08230901

Description Std. Pkg. Qty. 1 Quart (.9 liter) Squeeze Bottle 12/case 1 Gallon (3.8 liter) Jug 4/case 1 Quart (.9 liter) Squeeze Bottle, (Winter Grade) 12/case 1 Gallon (3.8 liter) Jug, (Winter Grade) 4/case

TECHLUBE™ CABLE EASE Engineered for use with fiber optic cable blowing systems and field proven with the Deluxe LW Blower. P-T Technologies Techlube™ Cable Ease is a pourable lubricant that provides waterproof lubricity on the inner walls of innerduct. Compatible with all types of cable jackets and conduit systems. Part Number 08230700

Description 1 Quart (.9 liter) Squeeze Bottle

Std. Pkg. Qty. 12/case

INNERDUCT COUPLINGS ETCO Double “E-Loc”® Innerduct Couplings are designed to join both smooth and ribbed HDPE innerduct, specifically for pneumatic methods of cable placement where air and water-tight integrity of the system is imperative, and where the joint is unrestrained such as in a vault, manhole or hand hole. The couplers are pressure tight to internal pressures above 200 psi when restrained or buried, and can maintain these pressures unrestrained, and are reusable. There are no metal parts and can be hand tightened with no special tools.

Part Number 08676510 08676511 08676512 08676513 08676514 08676515 08676516 08676517 08676518 08676520

64 5 Blue Heron Drive

Collegeville, PA 19426

Nominal Conduit Size 1" IPS 1.34" O.D. 1.42" O.D. 11⁄8" SIDR 9 1.50" O.D. SDR 11 11⁄4" True 1.125 I.D. 11⁄4" O.D. 1.60" O.D. 11⁄4" IPS 11⁄4" O.D. 11⁄2" True SIDR 9 11⁄2" True SIDR 9 11⁄2" IPS 2" IPS

(610) 831-5020

www.comstarsupply.com

Conduit Type Smooth Ribbed Smooth Ribbed Smooth Smooth Ribbed Smooth Smooth Ribbed Ribbed Smooth Smooth Smooth

Conduit O.D. (in) (mm) 1.315 33 1.340 34 1.420 36 1.460 37 1.500 38 1.530 39 1.575 40 1.600 41 1.660 42 1.700 43 1.830 46 1.830 46 1.900 48 2.375 60

Fax: (610) 831-5012

Coupling Length when tight (in) (mm) 6.25 159 6.25 159 6.25 159 6.25 159 6.25 159 6.25 159 6.25 159 6.25 150 6.25 159 6.25 159 8.25 210 8.25 210 8.25 210 8.50 216

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Notes

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

65

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Notes

5 Blue Heron Drive

66 Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Warranty Information A. FACTORY ASSISTANCE Condux International can provide further advice regarding any problems with the installation, service, assembly, or disassembly of the Deluxe LW Blower. Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The Deluxe LW Blower can be returned to the factory at any time for service or repair; however, a Return Material Authorization (RMA) must be obtained from Condux before shipping. Condux will not accept returned items without an RMA.

16.

B. LIMITED WARRANTY Condux International, Inc. extends the following warranty to the original purchaser of these goods for use, subject to the qualifications indicated: Condux International, Incorporated warrants to the original purchaser for use that the goods or any component thereof manufactured by Condux International will be free from defects in workmanship for the period of one year from the date of purchase. Provided such goods are installed, maintained, and used in accordance with Condux’s written instructions. Lack of routine maintenance as specified in the maintenance section of the User’s Guide will void the warranty. Components not manufactured by Condux International but used within the assembly provided by Condux International are subject to the warranty period as specified by the individual manufacturer of said component, provided such goods are installed, maintained, and used in accordance with Condux’s and the original manufacturer’s written instructions. Listed wear parts as called out in the User’s Guide are not covered under the warranty. Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under this limited warranty, and for any and all claims arising from the purchase and use of the goods, shall be limited to the repair and replacement of the goods that do not conform to this warranty. To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return Material Authorization (RMA). Once obtained, send the RMA along with the defective part or goods, transportation prepaid, to: Condux International, Inc. 145 Kingswood Road Mankato, MN 56001 USA THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM DATE OF PURCHASE. CONDUX ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THIS PRODUCT, EXCEPT AS STATED IN THIS LIMITED WARRANTY. CONDUX WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

67

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

www.comstarsupply.com

Condux International, Inc. P.O. Box 247 • 145 Kingswood Road, Mankato, MN 56002-0247 USA 1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442 Internet: http://www.condux.com • e-mail: [email protected]

68 5 Blue Heron Drive

Collegeville, PA 19426

© Copyright 2001, Condux International, Inc. Printed in USA Literature Part Number: 08780999 Revision Number: 2.0 (610) 831-5020 Fax: (610) 831-5012

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